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By C. I. Walker

Field tests at a number of large mineral processing operations have been undertaken to better understand the wear life impact of different aspects of pump design, materials of construction and maintenance procedures. Data are presented for wear rates, and typical result variability is explored. To improve the availability of pumping equipment in a milling circuit it is not only important to improve the wear life, but also reduce the variability in the wear life of components so that the incidence of premature failure is lessened. Localised gouging wear due to flow separation and turbulent eddy formation is often the point at which part-holing occurs. A number of improvements to the design of pump impeller and throatbush (suction side liners) to reduce the localised gouging wear are outlined. Also, results are presented on the use of composite materials (mix of metal, rubber and ceramic) for throatbush materials to protect specific areas against wear.

Jan 1, 2012

By Leslie McHattie, Sadek E. EI-Alfy

"The Maintenance Engineering Department at Carol Mining and Concentrating is currently in the process of introducing reliability concepts such as failure analysis, rework elimination, predictive maintenance, computerized maintenance history analysis, etc. to improve the over-all maintenance function in the mine and concentratormaintenance areas. Some current initiatives include:• Implementation ofan infrared thermographic scanning program.• Ultrasonic inspection of shafts for all critical equipment in the mine and concentrator areas.• Non-destructive testing of all major welds done by maintenance personnel.• Development of an effective vibration monitoring and analysis program for the production equipment in the mine (shovels, drills, haulage trucks, locomotives).• Failure analysis performed by maintenance engineers to identify the root cause of component failures on critical production equipment.• Computerized breakdown analysis to identify the recurring component failures which contribute significantly to high maintenance costs and production loss.• Implementation of a computerized maintenance management information system.This paper will outline the planned implementation ofthese initiatives, and others, and will also cover the status and results obtained to date."

Jan 1, 1992

By Gerald H. Luttrell, Lance Christodoulou, Jaisen N. Kohmuench, Michael J. Mankosa

The efficiency of the froth flotation process has long been known to be strongly dependent on particle size. For sulfide minerals, good recoveries are typically achieved in industrial flotation circuits for particles in the 30 to 200 µm size range. Particles outside this critical size are typically lost in industrial operations and rejected to tailings streams due to inherent constraints associated with the physical interactions that occur in the pulp and froth phases of conventional flotation equipment. In response to these limitations, a series of experimental studies were conducted to determine whether particles previously lost as tailings could be economically recovered using a suite of novel flotation technologies developed for upgrading ultra-coarse and ultra-fine particles in the industrial minerals industry. For the case of ultracoarse particles, a fluidized-bed flotation system called the HydroFloatTM separator was tested. The data obtained using this novel flotation device in both laboratory- and pilot-scale trials showed that good recovery of previously lost sulfide values up to 850 µm diameter could be achieved. Similarly, for ultrafine particles, a high-intensity cavitation-based column cell was tested. This technology, which utilizes highshear contacting of slurry and gas, was capable of recovering valuable ultra-fine sulfide that were previously lost due to the low capture efficiency of conventional flotation processes. The objectives of this article are (i) to describe the unique operating principles of these two advanced flotation technologies and associated ancillary classification equipment, (ii) to present laboratory- and pilot-scale experimental test data showing the metallurgical benefits of the proposed novel flowsheet for sulfide tailings processing, and (iii) to provide a generic cost-benefit analysis of the proposed system for recovering lost values in existing sulfide tailing streams.

Jan 1, 2016

By F. King, R. Sutherby, J. Been

With thousands of kilometers of buried oil and gas pipelines throughout the country, carrying flammable, high-energy hydrocarbons, the integrity and safety of this transportation and distribution network are paramount. The pipeline industry has the primary responsibility for pipeline safety and has in many ways taken the lead in dealing with safety issues. Over recent years, regulatory demands have increased, requiring operators to comprehensively evaluate their pipelines through indirect and direct inspections and to manage risk through integrity programs. Mechanistic and correlative models have been developed that assist in the prediction of pipeline integrity and the determination of reassessment intervals. These lifetime prediction models are based on decades of laboratory research as well as pipeline operating data, material data, and field monitoring data pertaining to soil conditions and CP. An overview is presented of an integrated approach towards the development of such models for the evaluation of external cracking and corrosion of transmission lines.

Jan 1, 2005

By R. A. L. Drew, J. P. Immarigeon, F. Jalilian, M. Jahazi

In the present work TLP bonding of Inconel 617 is investigated. The influence of the main processing parameters i.e. time and thickness of the interlayer were studied with optical and scanning electron microscopy. Boron containing interlayers with two different thicknesses were used and the influence of various holding times from 5 min to 24 hours on the microstructure of the bond region was investigated. The results indicated that, for the testing temperature of 1065°C and holding times above 2 hours with an interlayer of 25.4 microns thick no liquid phase was observed. The same phenomenon occurred only after 6 hours for a 76.2 microns thick interlayer. Precipitate growth started at grain boundaries and continued inside the grains. The composition, size and morphology of the precipitates were studied using electron microprobe analysis. No noticeable changes were observed in the grain size of the base metal with increasing holding times.

Jan 1, 2004

By X. J. Guo, Q. K. Wang, S. P. Zhong

With depletion of traditional clean copper reserves and fast expansion of the global copper demand and smelting capacity in the past decade, more and more copper smelters have to treat copper concentrate with increasing content of complex arsenic-bearing minerals. Developing economically viable and environmentally reliable methods and approaches for arsenic control in copper smelting has become more critical for sustainable growth of the copper industry. This paper will report the recent effort of Zijin Mining Group Ltd. in developing processes for improving arsenic control and management in the Zijin Copper Smelter. The arsenic distribution and balance data for matte smelting, converting and refining operations in Zijin Copper Smelter is reviewed for understanding of the current challenges in arsenic control. The processes developed for treating the arsenic bearing waste acid bleed stream from the smelting-converting off-gases wet cleaning circuit and the arsenic sludge produced in the refining electrolyte purification circuit for arsenic disposal are discussed. INTRODUCTION With fast expansion of the global copper smelting capacity to meet the world copper demand and depletion of traditional clean copper reserves, more and more copper smelters have to treat copper concentrate with an increasing content of complex arsenic-bearing minerals. China is the world largest copper consumer and also has the largest copper smelting and refining capacity, but majority of its smelting capacity relies on supply of imported copper concentrate. In order to meet the increasing copper demand and ease the tight supply of clean copper concentrate, the Chinese copper industry has to look at the domestic opportunity of developing non-traditional copper resources, specifically those of lower grades, more complex mineralogy, and increasing level of deleterious elements especially arsenic and also process imported copper concentrate with increased arsenic content. Due to a significant and growing environmental issue associated with arsenic contamination, developing economically viable and environmentally reliable methods and approaches for arsenic management and control in unlocking the maximum value of such arsenic bearing copper resources has become more critical for sustainable growth of the industry.

Jan 1, 2019

By F. Parada L

Two copper concentrate with medium and high enargite content were leached in a 3 L autoclave reactor under conditions based on the CESL process. Copper, arsenic, sulfur and iron were checked in all the experiments and antimony, zinc and molybdenum were evaluated in selected tests. The 98% of the obtained copper extraction is agree with others authors, but the behavior of arsenic, iron an sulfur have some differences. The solid residue was characterized by chemical analysis, DRX and QEMSCAN®. Finally a comparative analysis with neutral roasting as an option for the treatment of this concentrate is done.

Jan 1, 2014

By A. Fortin, C. Fréchette, M. Kreuh

Éléonore project is a gold ore processing plant at a mine site located near James Bay, Quebec, Canada. SNC-Lavalin was mandated by Goldcorp to perform EPCM services on the ore processing plant and permanent infrastructures of the project following an internal pre-feasibility study. The project incurred considerable challenges due to fast-tracking from a pre-feasibility to detailed engineering and construction. The paper reviews how the EPCM was carried out. Some of the challenges resulting from skipping the feasibility study stage are discussed. The paper also presents how multiple offices across Canada were used for the engineering design.

Jan 1, 2015

By D. J. Sapsford

This paper details results from laboratory simulation of an innovative underground bioleaching process. The underground reactors are periodic flushed with recycled leachate to remove uranium that accumulates within the reactor water. This leaching cycle has been recreated within the laboratory. This study examines the influence of varying cycle protocol on uranium leaching. Protocol variants examined include variation of flushing frequency, flush volume, leachate recycle, nutrient solution (NPK) addition to reactors and Fe(III) sulphate addition to reactors. The presented data highlight the dramatic improvements in uranium recovery that might be achievable by varying the operating protocol for the actual underground reactors.

Aug 1, 2010

By M. Moats

World copper refining tankhouse practices have been surveyed. This survey is a supplement to previous surveys that have been carried out in the 1987, 1991, 1995, 1999, 2001 and 2003. On a world basis, process technology trends include the further installation of automated electrode handling systems including permanent cathode systems, automatic anode preparation and cathode handling machines, section switches, fully automatic cranes and polymer concrete cells. General plant process control has increased with more automation of material handling in the copper refining tankhouse. The general trend for most greenfield copper refining projects remains in eastern Asia.

Jan 1, 2007

By Don Peel, Jeremy Richards

Abstract - Aggregates (sand, gravel, and crushed stone) are low unit-cost products extracted in very large volumes for the construction of buildings, roads, and other infrastructure essential to modern society. Because of their low unit value, transportation costs are a key factor in resource economics, and deposits are commonly developed close to market (i.e., close to towns and cities, or along low-cost transportation corridors). This proximity results in potential conflict with residents over land use, disturbance, and pollution. Management of aggregate resources in Alberta is examined in the light of resource geology and distribution, and governance. A case history of development of the Calahoo-Villeneuve deposit is described, and the conflicts between residents and developers that led to establishment of an Area Structure Plan (ASP) are explored. The plan sets limits to, but at the same time safeguards, resource extraction, and defines terms for compensation to residents through a voluntary levy on production (Community Enhancement Fund). This fund is used to support community activities and to pay for a groundwater monitoring program. The ASP is examined within the context of the "Seven Questions to Sustainability" as set out by Mining,Minerals and Sustainable Development-North America (2002). It is concluded that the ASP, for the most part, provides a good model for conflict resolution and sustainable resource development, which could usefully be applied in other jurisdictions. The ASP was developed at a municipal level, and adoption at a provincial level would aid sustainable development of aggregate resources across the province.

Jan 1, 2003

By E. Essadiqi, P. Poruks, D. Boyd, D. Emadi, I. Yakubtsov, T. Turi

This paper reviews the results of an extensive study of microstructures and mechanical properties in bainitic linepipe steels. The research was carried out as a collaborative project between Queen's, Stelco and CANMET. Basic studies of phase transformations and mechanical properties in these steels established important relationships between processing schedule and microstructure evolution, and between final microstructure and mechanical properties. The best combination of strength and toughness properties is obtained with a microstructure comprising a matrix of intragranularly-nucleated bainite (`acicular ferrite - AF') and small (~ 0.5 µm) dispersed particles of martensite (`M/A'). We describe this as a dual-phase AF+M/A microstructure. An experimental study on 15-mm thick plate determined the window of steel composition and processing parameters which gives the dual phase AF+M/A microstructure. The minimum strength and toughness properties for Grade 621 (X90) linepipe steel can be achieved by either a lean steel composition (0.04C-1.77Mn-0.04Cr¬0.32Mo-0.31Ni-0.29Cu-0.08Nb) with extreme processing parameters, or by a higher alloy composition (0.04C-2.07Mn-0.50Cr-0.51Mo-0.04Nb) with a more industrially realistic processing schedule. It is proposed how this approach could be extended to obtain higher strength linepipe grades.

Jan 1, 2005

By R. G. L. McCready, R. O. van Everdingen, M. Kalin, R. van Everdingen

"This paper is based on data generated between October, 1986 and October, 1989, during the implementation of an Ecological Engineering close-out for a zinc mine in Northern Ontario, where 690000 tonnes of tailings contain 41.1% pyrite and 4.1% pyrrhotite. The objective was to determine rates of sulphide oxidation and iron precipitation in the tailings. Those rates are relevant for the assessment of the long-term effectiveness of biological systems employed in the removal of heavy metals from contaminated drainage issuing from tailings.Data were collected on the topography and stratigraphy of the tailings basin, subsurface temperatures and groundwater levels, and chemical analyses were made of water samples collected from a number of piezometers. The thickness of unsaturated tailings varied widely between individual piezometer locations; annual maxima ranged from 0.67 m to 3.55 m, and annual minima from 0 to 2.68 m. Sulphate concentrations ranged from 36 mg/L to 20180 mg/L; iron concentrations from 0.36 mg/L to 9938 mg/L; and zinc concentrations from 0.33 mg/L to 1123 mg/L.The geochemistry of the piezometer samples suggests that some of the initial Fe content, resulting from metal sulphide oxidation, is subsequently precipitated in the tailings pile and, possibly, in the underlying unconsolidated sediments, probably in the form of iron-hydroxide and Na-jarosite. Other metals such as Zn may be co-precipitated with Fe. The discharge of a portion of these metals to the environment would be delayed by this process. Some of the initial sulphate may also be lost from solution, probably by precipitation of gypsum; approximate saturation degrees for gypsum ranged from -3.27 to +0.47. The precipitated minerals will somewhat decrease the porosity and permeability of the tailings.Sulphide-oxidation rates, calculated using the analytical results and the estimated amount of annual recharge at the tailings site, average 0.0057 mol/kg/yr. Calculated iron-precipitation rates average 0.000386 mol/kg/yr. It is concluded that the characteristics of seepage from mining wastes may change with time, reflecting the solubilization of precipitated secondary minerals."

Jan 1, 1992

By P. E. Cavanagh

Abstract Many investigators have been interested in developing some non-destructive method for detecting or determining the changes in physical properties in steel occurring during endurance tests or normal service life of a part which fails in fatigue. This paper presents a broad discussion of some of this work and the possibilities of developing useful test procedures based on some of the information obtained in the past. Changes in magnetic properties, electrical resistance, damping capacity, X-ray diffraction patterns, and remaining fatigue life at load different from service load have all been investigated as possible means for following the sequence of events during fatigue failure. In some special instances, tests such as these may be used to predict fatigue failure. As an in stance of practical application of the continuous determination of changes in magnetic properties during fatigue, a brief account is given of work done in non-destructive inspection of mine hoist-rope. As a result of extensive experiments and field crisis, it has been found possible to detect the beginnings of failure in a wire rope in service. The test method used will detect plastic deformation in a wire rope, no matter what its cause. There is no possibility of determining the remaining useful life of a rope by calibrating changes in magnetic properties in terms of remaining fatigue life. A change in magnetic properties at a point in a rope may indicate a decrease or increase in fatigue life, depending on the overload history of the rope. A continuing change in magnetic properties ac a point, however, does reliably indicate a developing weak point which will eventually lead to failure. The important point about any change in magnetic properties is not the magnitude of the change, but whether or not it continues.

Jan 1, 1947

By D. Nie, M. Ren, T. Mo

This paper studied the phenomenon of room temperature creep deformation at crack tip and its effect on fatigue crack growth rate of a X-70 pipeline steel using compact-tension (CT) specimen on a MTS 810 testing machine. Time-dependent deformation at the crack tip under constant load was observed in this steel at room temperature and the amount of deformation produced was seen to depend on loading rate and the magnitude of stress intensity factor. It is found that there exists a critical stress intensity factor below which the deformation decreases with time when the applied load remains constant. It is also found that the occurrence of room temperature creep obviously affects the subsequent fatigue crack growth rate. The observed behavior was explained based on dislocation theory.

Jan 1, 2005

By W. Cholewa, T. S. Golosinski, J. Wedzicha

"Power requirements of belt conveyor drives are usually estimated based on the calculated belt tension which equals the sum of unit resistances to motion which the belt has to overcome. In most situations, the value of various unit resistances can be accurately predicted using published information (5,6,8,12). A simpler approach calls for use of standard formula and tabulated values of related factors which reflect various features of both the conveyor and the transported material (2,3,7) . None of these approaches is reliable when materials with unique properties are conveyed, nor if applied to conveyors working in extreme climatic conditions. Such is the case of oil sand mines in northern Alberta.There the bitumen content of oil sand causes it to behave in a unique manner. Furthermore the conveyors operate year around, with winter temperatures often lower than - 40°C. It was the objective of presented investigations to quantify the power requirements of conveyors, and related resistance to motion for the conveyors used in oil sand mines during winter operations.The other objective was to quantify the drive power requirements of oil sand conveyors during start-up. These requirements are usually much higher than those during norm al operation, and their quantification is of paramount importance for operation of large conveyors."

Jan 1, 1992

By A. L. Williamson

Bio-mining is a cost-effective, energy efficient and potentially environmentally protective method of exploiting a variety of ore deposits, from high-grade base metal deposits of nickel to lower-grade uranium and rare earth deposits such as are found in the uraniferous quartz-pebble conglomerate beds of the Quirke Syncline, Elliot Lake, Ontario. The effectiveness of bio-mining in Elliot Lake depends on the success of bacterially-influenced dissolution of metals of economic importance. The determination of both the dissolution efficiency and rate controls for uranium and rare earth elements from bio-extraction processes is critical to assess the potential for success of bio-mining along the Quirke Syncline. This poster provides an overview of proton-mediated biogeochemical dissolution of more than 50 elements, including uranium and rare earth elements from samples of the low grade uraniferous ore collected as drill core from the Elliot Lake area. The elemental data is quantified using advanced spectroscopic tools (ICP-MS and ICP-AES) to analyze solutions obtained from a series of environmentally controlled biologically-mediated uranium ore extraction experiments. The findings are being to guide design of larger scale bio-leaching experiments to further assess the potential for success of bio-mining along the Quirke Syncline.

Aug 1, 2010

By F. Simon, A. Roth, M. F. Zaeh

Applying Friction Stir Welding in an industrial environment requires knowledge about the robustness of the welding process against imperfections in the joint line resulting from production deviations of the parts to be joined or from improper clamping devices. In this work the influence of gaps on the weld quality of friction stir welded butt joints of the aluminum alloy EN AW-5083-H111 is investigated in detail using the method Design of Experiments. As independent input variables, the rotation speed, the feed rate, the tilt angle, the lateral tool offset and the gap width were chosen. Tensile strength was selected as a measure for the joint quality. Moreover, the fundamental response variables of the FSW process, such as weld temperature, axial force and spindle torque, were recorded and integrated in the empirical process model derived by regression analysis. It was found that each response variable decreases with increasing gap width, whereas the largest impact was identified for the axial force and the temperature at the weld surface. In order to improve the joint strength for a given gap width, increasing the rotation speed and the tilt angle or lowering the feed rate, respectively, proved to be a suitable approach. However, interactions between the tilt angle and the rotation speed have to be considered.

Jan 1, 2014

By Libao Zhu, David J. Williams, Nazife Erarslan

"Statistics show that the drawbell in underground mines is usually subjected to significant damage by impact loading due to falling ore. Drawbell damage causes a large quantity of residual ore to remain on the drawbell, thus leading to a huge waste of ore resources. In this study, the Cavity Monitoring System (CMS) and Surpac software were employed to visualize the 3-D damage. Also, the Discrete Element Method (DEM) was employed to perform simulations of the falling ore to investigate the damage evolution of drawbells under repeated ore impact and obtain the dynamic damage accumulation mechanism. The reason of drawbell damage was found due to the micro-shear cracks. The numerical simulations of a drawbell damage process under repeated impact loading showed the main failure type was shear failure and this type damage was found increasing with more ore falling. INTRODUCTIONDrawbells are an important part of underground mines and play a significant role in ore recovery in terms of safety, economy and efficiency (Brunton et al., 2010; Hustrulid & Bullock, 2001; Trueman et al., 2002). In most cases, blasted ore is gravitated along the drawbell and finally arrives at the footwall of the drawpoint. However, some of the blasted oversize ore blocks clog the drawbell road and those ore pieces are called hang ups (Penswick, 1997). However, any damage on a drawbell is believed to be the reason for these hang-ups. In the literature, researchers have reported that the stability of the draw-point is influenced by the stress distribution above and near the drawbell (Butcher, 1999; Neverov & Neverov, 2013). Much research in the literature has been done on draw-points in underground mines. In fact, rockfalls cause very serious damage on a small impact area in a very short time (Volkwein et al., 2011). Hoek (2000) pointed out that the blasted ore causes progressive ravelling and even collapse of the drawpoint, thus the ore in the stope is abandoned. In this paper, the Cavity Monitoring System (CMS) was employed to obtain the damage profile of a drawbell due to the impact of rockfalls and to confirm the residual blocking ore on the damaged drawbell. Then, the drawbell damage evolution due to repeated falling ore was simulated by the Discrete Element Method (DEM)."

Jan 1, 2015

By Youngsoo Song, Hyunjung Kim, Junhyun Choi, Siyoung Q. Choi, Gahee Kim

In this study, for the first time, to confirm the effect of bacterial growth phase on the malachite flotation were investigated in a well-controlled Hallimond tube system. The test results showed that the bacteria in the stationary phase exhibit two-fold greater floatability than those in mid-exponential phase. To understand the observed flotation behavior, complementary cell characterization tests and cell attachment tests were conducted. Interestingly, the bacteria at both phases exhibited similar surface properties as well as almost identical amount of cells attached onto the malachite, suggesting that the growth phasedependent flotation behavior cannot be attributed to the variation of cell surface properties and the extent of cell adsorption. On the other hand, cell detachment tests revealed that the amount of cells detached from the malachite surface is greater for the mid-exponential phase than the stationary phase due to the higher fluid drag applied to the cells at the mid-exponential phase, which was explained by the differences in the size and shape of attached bacteria onto the malachite surface. These morphological characteristics were found to cause the bacteria of mid-exponential phase to be separated highly sensitive and easy from malachite surface due to the fluid flow. Second, scale-up selective bioflotation tests were carried out in a 1 L Denver cell in malachite–silica binary mixture systems. Through the tests, we optimized the cell concentration and the malachite fraction in the feed. Overall, high malachite selectively was observed under optimized conditions (both recovery and grade showed more than 90%). The trend was in agreement with classical DLVO interaction energy profiles, which show the relative magnitudes of the adhesive forces between the mineral and the attached cell under equal hydrodynamic conditions.

Jan 1, 2016